Design of tortuous path control valve trim

ABSTRACT

A valve component for controlling fluid flow comprises a body having a first surface and a second surface. At least one tortuous flow channel extends between the first surface and the second surface. The flow channel is at least partially defined by a floor portion and a ceiling portion. The body is formed as one-piece by additive manufacturing to concurrently define the flow channel as a void space. At least one of the floor portion and ceiling portion is disposed at an acute angle relative to a plane containing a layer of material forming the body.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to apparatus that control fluidflow. Particularly, the present invention relates to an improvedcomponent of a fluid flow control valve and to manufacturing thecomponent.

2. Discussion of Prior Art

It is known that some fluid flow applications have valve assemblies tocontrol fluid flow through the valve assemblies so as to minimize noise,vibration and cavitation. One such known valve assembly includes atubular cage that fluid flows through. The cage has multiple flowchannels through which the fluid flows and that are designed to controlthe velocity and pressure of the fluid through the cage and valveassembly.

The cage of the valve assembly is typically made from a series ofstacked and relatively thin (about an average 0.125 inch thickness)cylindrical plates. The cage has numerous inlets and outlets formedalong concentric circular peripheral surfaces of the plates. Flowchannels are formed in the plates between the inlets and outlets bymachining or cutting so flow is directed in the radial andcircumferential directions within a given plate. The plates are stackedin a specific relative orientation and typically attached together bybrazing.

Trying to manufacture a high quality known cage stack of plates in areasonable lead time for a reasonable cost has been a challenge. Thereare inherent problems and disadvantages with manufacturing the knowncage having a stack of plates.

For example, machining or stamping the plates can introduce unwanteddebris that may attach to a plate or create edge surfaces that requiredeburring. Proper repeated stacking and aligning the separate plates canbe difficult. It can also be a challenge to then hold the stacked andaligned plates during the brazing operation in order to achieve a goodquality braze every time. One such alignment scheme is to provide extramaterial lobes with alignment holes which are machined off after brazingand, therefore, add manufacturing lead time and cost. This machining canalso introduce unwanted contaminants the can enter flow channels, socare must be taken to block the flow channels or remove thecontaminants.

Brazing itself also may present problems. Braze may be applied to theplates in various ways. To achieve an even and relatively thin layer ofmolten braze between adjacent plates, the plates must be flat. Anywaviness of the plates will create areas where the braze will havedifficulty flowing in an even and relatively thin manner to properlyadhere adjacent plates together and, thereby, cause a lack of structuralintegrity. Plates can be ground flat but so doing increasesmanufacturing lead time, cost and the possible introduction of unwantedcontaminants.

The known stacked plate-type cage manufacturing process generallyrequires that the cylindrical inside surface of the stack of brazedplates be machined to achieve the precision diameter and finish requiredto fit other components of the valve assembly. Machining the insidesurface of the known cages can generate unwanted contaminants that canfind their way into flow channels. It is very difficult to remove thecontaminants and time consuming and costly to take measures to try toprevent ingress of the contaminants.

Thus, a need exist for an improved cage structure that does not sufferfrom the disadvantages and drawbacks of known plate-type of cages andthe manufacturing processes used to produce them.

BRIEF DESCRIPTION OF THE INVENTION

The following summary presents a simplified summary in order to providea basic understanding of some aspects of the arrangements and/or methodsdiscussed herein. This summary is not an extensive overview of thearrangements and/or methods discussed herein. It is not intended toidentify key/critical elements or to delineate the scope of sucharrangements and/or methods. Its sole purpose is to present someconcepts in a simplified form as a prelude to the more detaileddescription that is presented later. This summary is not intended to beused to limit the scope of the claimed subject matter.

A valve component cage for controlling fluid flow, according to oneaspect, comprises a body having a first surface and a second surface. Atleast one tortuous flow channel extends between the first surface andthe second surface. The flow channel is at least partially defined by afloor portion and a ceiling portion. The body is formed as one-piece byadditive manufacturing to concurrently define the flow channel as a voidspace. At least one of the floor portion and ceiling portion is disposedat an acute angle relative to a plane containing a layer of materialforming the body.

A trim cage for controlling fluid flow, according to another aspect,comprises a unitary body having a substantially tubular configurationwith a longitudinal central axis. The body has an inner surface and anouter surface. At least one tortuous flow channel extends through thebody from the inner surface to the outer surface for fluid flowtherethrough. The tortuous flow channel includes at least two sections.Each section of the flow channel is offset relative to an adjacentsection. Each section of the flow channel has an axial floor portion andaxial ceiling portion. Each of the axial floor portions and axialceiling portions are disposed at an acute angle relative to a planeextending normal to the longitudinal central axis of the body.

A method of manufacturing a unitary trim cage, according to yet anotheraspect, comprises the steps of providing material to define a closedbody base with an inner opening surface and an outer surface. Materialis added to the body base along a lay down direction and in such amanner to maintain the inner opening surface and define at least onetortuous flow channel extending between the inner opening surface andthe outer surface. The tortuous flow channel includes of a plurality ofsections. Each section of the flow channel is offset relative to anadjacent section. The surfaces defining the flow channel areaccomplished without internal support. At least a portion of eachsection extends at an acute angle relative to direction of additive laydown. Material is added to define a closed body cap in such a manner tomaintain the inner surface and the outer surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description and drawings set forth certain illustrativeembodiments, aspects and implementations. These are indicative of but afew of the various ways in which one or more aspects may be employed.Further features of the invention will become apparent to those skilledin the art to which the invention relates from reading the followingdescription with reference to the accompanying drawings, in which:

FIG. 1 is an overall perspective view of a trim cage, constructedaccording to one aspect;

FIG. 2 is a perspective view of the trim cage, similar to FIG. 1, partlyin phantom to show some flow channels dispersed throughout the trimcage;

FIG. 3 is a top view of the trim cage, illustrated in FIG. 2, showingthe flow channels;

FIG. 4 is an enlarged perspective view of one of the flow channels inthe trim cage illustrated in FIGS. 1-3;

FIG. 5 is a perspective view partly in section of the tortuous flow pathin the flow channel illustrated in FIG. 4;

FIG. 6 is an enlarged view of the cross-sectional shape of the flowchannel according to one aspect;

FIG. 7 is an enlarged view of the cross-sectional shape of the flowchannel according to another aspect;

FIG. 8 is an enlarged view of the cross-sectional shape of the flowchannel according to yet another aspect;

FIG. 9 is an enlarged perspective view of an alternative flow channelshape according to another aspect;

FIG. 10 is an enlarged perspective view of an alternative flow channelshape according to another aspect;

FIG. 11 is an enlarged perspective view of an alternative flow channelshape according to another aspect; and

FIG. 12 is an enlarged perspective view of an alternative flow channelshape and manufacturing process according to yet another aspect.

DETAILED DESCRIPTION OF THE INVENTION

The claimed subject matter is described with reference to the drawings,in which like reference numerals are used to refer to like elementsthroughout the description. In the following detailed description, forpurposes of explanation, numerous specific details are set forth inorder to provide an understanding of the claimed subject matter. It willbe understood, however, that the claimed subject matter can be practicedwithout these specific details.

An improved control valve component, such as a trim cage and method ofmanufacturing the trim cage are disclosed that do not suffer from thedisadvantages and drawbacks of previously known stacked plate-type cagesand their associated manufacturing processes. The improved trim cage hasa plurality of flow channels with a specific configuration that allowsthe control valve to be “printed” by a direct metal laser meltingprocess to define the flow channels as void spaces without the need forinternal support. Direct metal laser melting is an additivemanufacturing technique that uses a laser as the power source to sinterpowdered material (typically metal), aiming the laser automatically atpoints in space defined by a 3D model, binding the material together tocreate a solid structure.

The improved trim cage is used in a control valve assembly (not shown).In addition to the improved trim cage, the control valve assemblyincludes a valve body, a cage retainer and a valve plug. The valve bodyhas an inlet, an outlet, and a conduit extending between the inlet andthe outlet. The trim cage is a generally cylindrical member that has aplurality of flow channels and is disposed within the conduit. The cageretainer holds the cage in the valve body within the conduit of thevalve body. The valve plug closely fits within the trim cage and ismovable relative to the trim cage. The valve plug is adapted to becoupled to an actuator. The actuator controls reciprocal displacement ofthe valve plug between a closed position and an open position. Uponmovement of the valve plug towards the open position, fluid is free toflow through the plurality of flow channels in the trim cage.

An improved trim cage 20, according to one aspect for use in the controlvalve assembly, is illustrated in FIG. 1. The trim cage 20 has a body 21with a substantially tubular shape with a longitudinal central axis A.The body 21 is formed as a unitary or one-piece component which providesadvantages over previously known stacked plate-type cages. The trim cage20 includes a base 22 defining the lower end of the body 21, as viewedin FIG. 1. The trim cage 20 also includes a cap 24 at the upper end. Thebody 21 of the trim cage 20 has a cylindrical inner surface 26 disposedabout the longitudinal axis A and extends between the base 22 and cap24. The body 21 of the trim cage 20 also has a cylindrical outer surface28 that is coaxial with the inner surface 26 and extends between thebase 22 and cap 24.

As best seen in FIGS. 2-5, the trim cage 20 has a plurality of tortuousflow channels 40 extending through the body 21 and between the innersurface 26 and the outer surface 28. The flow channels 40 are formed ina columnar and circumferential array as void spaces as the body 21 isbeing manufactured. The body 21 is integrally formed as one-piece bysuccessive layer material additive manufacturing, or simply additivemanufacturing, that defines the flow channels as void spaces within thebody during manufacture. The flow channels 40 are formed during themanufacture of the body 21 without the need of support material todefine the flow channel.

While sixteen columns and eleven circumferentially arranged rows of flowchannels 40 are illustrated in the trim cage 20, it will be apparentthat any suitable number of columns and circumferentially arranged rowsof flow channels may be utilized. For example, it is contemplated thatthe number of flow channels 40 formed in the trim cage 20 could be inthe range of between one hundred to several thousand or more dependingon the size of the trim cage, size of the valve assembly that the trimcage is used in and the volume of fluid that will flow through the trimcage and valve assembly. Also, there are certain trim cages that containa relatively small number of plates for a short distance of the valvetravel and even other styles of valve trim. These trim cages could veryfew flow channels (e.g., as few as 2 flow channels).

Each of the flow channels 40 has an inlet 42 (FIGS. 2-5) at the insideof the trim cage 20 at the inner surface 26. Each of the flow channels40 also has an outlet 44 at the outside of the trim cage 20 at the outersurface 28. The direction of fluid flow F (see FIG. 5) in the flowchannels 40 is generally in a radially outward direction from the innersurface 26 through inlet 42 to the outer surface 28 through the outlet44 (see FIG. 3). Each flow channel 40 (see FIG. 5) forms a labyrinthstructure that causes fluid to flow in a tortuous path. In theillustrated example, the flow path F essentially varies or changesdirection that is substantially parallel to the longitudinal centralaxis A of the trim cage 20 at least for a portion of the flow channel40. The flow channel 40 may be formed, if desired, so that it directsflow in a direction substantially parallel to the longitudinal centralaxis A for a distance that is greater than previously possible with thestacked plate-type cages. That is, since the plate was typically onlyabout 0.125 inch in thickness the flow path F can be designed so thatflow is directed for an axial distance that is greater than what couldbe done with stacked plate-type cages. It will be apparent that the flowchannel 40 can be formed so that the flow path can be customized to flowin any desired direction. For example, the flow channel 40 may bedesigned to flow in a partially circumferential direction, either in asubstantially arcuate or linear flow direction, for at least a portionof the flow path. It will also be apparent that the flow path could be acombination of axial and circumferential flow.

The size and configuration of each of the flow channels 40 may be dependon the fluid flowing therethrough. For example, if an incompressiblefluid, such as a liquid, is flowing through the trim cage 20, thecross-sectional area of the flow channels 40 will be substantiallyconstant as it extends from the inlet 42 to the outlet 44. By way ofexample for incompressible liquid flow, the cross-sectional area of theflow channel 40 is illustrated in FIG. 6, according to one aspect, andwill be substantially the same for the entire length of the flow channel40. The height H of an inlet 42 of the flow channel 40 can be about0.125 inch and the width W can be about 0.125 inch. The height H of anoutlet 44 of the flow channel 40 having a gas flow therethrough can beabout 0.125 inch and the width W can be about 0.125 inch. Any suitabledimensions for the height H and width W can be used. It will also beapparent that a flow channel 40 with a single inlet 42 and a singleoutlet 44 could be used as opposed to the bifurcated flow channel with apair of outlets, as illustrated in FIGS. 4 and 5.

For example, if a compressible fluid, such as a gas, flows through thetrim cage 20, the cross-sectional area of the flow channels 40 mayincrease in the direction of flow from the inlet 42 to the outlet 44.For example, the cross-sectional flow area of the flow channels 40 mayincrease in size by a factor of two or more. By way of example for gasflow, the cross-sectional area of the flow channel 40 is illustrated inFIG. 6. The height H of the flow channel 40 of an inlet 42 can be about0.125 inch and the width W can be about 0.125 inch. The height H of eachoutlet 44 of the flow channel 40 having a gas flow therethrough can beabout 0.25 inch and the width W can be about 0.25 inch. It is to beappreciated that any suitable dimension can be used.

As illustrated in FIGS. 2-4, each of the flow channels 40 for use withgaseous flow applications has an inlet or primary flow channel portion46 and a bifurcated or pair of secondary flow channel portions 48extending from the primary flow channel portion 46 of the flow channel.Each of the secondary flow channel portions 48 is connected to theprimary flow channel portion 46 by respective substantiallycircumferentially extending connecting portion 60. In this aspect, theoverall cross-sectional flow area at the outlets 44 of the flow channel40 can be four or more times the cross-sectional flow area at the inlet42 by the width W increasing while the height H remains relativelyconstant. The connecting portions 60 are arranged to direct fluid flowin an orthogonal direction relative to the radial extent from theprimary flow channel portion 46.

Each flow channel 40 also includes a plurality of sections 80 a-80 j(FIGS. 4-5). The exact number of sections 80 a-80 j in a given flowchannel 40 will depend on numerous variables, such as the size of thetrim cage 20, the fluid that will flow therethrough, the cross-sectionalflow area of the flow channel and the length of the flow channel. It isworth noting that the primary driver for the number of sections isactually the pressure drop across the stack. The number of sections 80a-80 j that are illustrated in FIG. 4 are by way of example. Sections 80a-80 e comprise the inlet or primary flow channel portion 46. Sections80 a-80 j comprise each of the outlet or secondary flow channel portions48.

The sections 80 a-80 j are alternating offset in the axial directionalong the axis A relative to one another. For example, section 80 b islocated a predetermined distance above section 80 a and the section 80 cis then located a predetermined distance below section 80 b, asillustrated in FIGS. 4 and 5. The center of the sections 80 a and 80 ccan be located along a first line extending radially from thelongitudinal central axis A. The center of the sections 80 b and 80 dcan be located along a line extending radially from the longitudinalcentral axis A. The first radially extending line can be spaced from thesecond radially extending line in a direction substantially parallel tothe longitudinal central axis A. This alternating pattern repeats itselffor the entire length of the flow channel 40 and forms the labyrinthstructure to create the tortuous flow path F of the flow channel 40 asillustrated in FIG. 5. It will also be apparent that the sections 80a-80 j could be offset in a circumferential alternating and repeatingdirection relative to one another.

As illustrated in FIG. 6, the cross sectional shape of the flow channel40 is in the general form or shape of a chevron 82. That is the chevron82 shape has a V-shaped roof or ceiling portion 84 and a V-shaped floorportion 86. Each leg of the ceiling portion 84 and floor portion 86 areactually planar surfaces extending in the direction of fluid flow F fora predetermined distance. The ceiling portion 84 and the floor portion86 are joined together by substantially parallel extending planarsurfaces 88. The surfaces 88 extend generally in the direction of thelongitudinal central axis A of the trim cage 20. The legs of the ceilingportion 84 and floor portion and axial ceiling portion 86 of the flowchannel 40 are a pair of planar surfaces that intersect at an acuteangle relative to one another. Each of the surfaces of the legs of theceiling portion 84 and floor portion 86 are also disposed at an anglerelative to a plane extending normal to the longitudinal central axis Aof the body 21. The angles that the legs of the ceiling portion 84 andthe legs floor portion 86 are disposed do not necessarily have to be thesame angle. It is the angled surfaces of the legs of the ceilingportions 84 and the legs floor portions 86 that enable use of the directmetal laser melting manufacturing process without having to support theangled surfaces during manufacture.

The tortuous flow path F of the flow channel 40 of the trim cage 20,according to any aspect disclosed herein, subjects the fluid to inertiallosses as it is redirected through each turn in the flow path. Thetortuous flow geometry of the of the flow channel 40 of the trim cage20, according to any aspect disclosed herein, creates a series ofkinetic energy losses. This control of energy is highly effective fornoise attenuation due to the staged control of the fluid velocity. Thiscontrol is accomplished by directing the fluid through the flow channels40 that are designed with multiple sections consisting of substantialflow path redirections and expansions.

Each of the flow channels 40 of the trim cage 20, according to anyaspect, that is designed with an expansion in flow area for gaseousapplications, is essential for managing velocity that would otherwiseincrease as the pressure is reduced across each section. The expandingarea is designed to compensate for the volumetric expansion of the gas,limiting fluid velocity as the pressure is reduced. Velocity control ofthe flowing fluid is one of several important factors for maintainingrelatively low aerodynamic noise levels within the valve assembly andtrim cage 20.

A modified chevron cross-sectional shape of the flow channel 40 isillustrated in FIG. 7. The modified chevron 102 has a ceiling portion104 and a floor portion 106. The ceiling portion 104 and the floorportion 106 are joined together by a pair of substantially parallelextending surfaces 108. The parallel extending surfaces 108 extendgenerally in the direction of the longitudinal central axis A of thetrim cage 20. The ceiling portion 104 includes a plurality of relativelyshort linear sections 110 forming the lower part of each of the legs ofthe ceiling portion 104. Any suitable number of relatively shortsections 110 may be used. This type of relatively gentler cornertransition configuration for the flow channel 40 may be desirable incertain circumstances, for example to smooth flow, reduce turbulenceand/or reduced stress concentrations. While the floor portion 106 isillustrated as having a pair of legs that are linear, it will beapparent that each of the legs of the floor portion could be shaped withrelatively short linear sections as in the ceiling portion 104. It willalso be apparent that the relatively short linear sections 110 could beutilized at the apex of the ceiling portion 104 and a floor portion 106.Each of the relatively short linear sections 110 are disposed at anacute angle, preferably at least 45°, relative to a plane extendingnormal to the longitudinal central axis A of the trim cage 20.

Another modification of the cross-sectional area of the flow channel 40is illustrated in FIG. 8. The modified cross-section chevron 120 has aroof or ceiling portion 124 and a floor portion 126. The roof or ceilingportion 124 and the floor portion 126 are joined together bysubstantially parallel extending surfaces or walls 128. The parallelextending surfaces 128 extend generally in the direction of thelongitudinal central axis A of the trim cage 20. The roof or ceilingportion 124 includes a pair of relatively short arcuate sections 130 aand 130 b forming the lower part of each of the legs of the roof orceiling portion 124. It will be apparent that any suitable number ofrelatively short arcuate sections 130 a and 130 b may be used. This typeof configuration for the flow channel 40 may be desirable in certaincircumstances, for example to smooth flow and/or reduce turbulence. Asillustrated in FIG. 8, the roof or ceiling portion 124 includes twoarcuate portions 130 a, 130 b of different radii. Arcuate portion 130 ais defined by a radius that is less than the radius of the arcuateportion 130 b. The arcuate portions 130 a, 130 b are located at theuppermost portion of the surface or wall 128 where it starts to form theroof or ceiling portion 124. While the floor portion 126 is illustratedas each of its legs having at least one relatively short arcuate section130 c. It will be apparent that any suitable number of relatively shortarcuate sections 130 c may be used in each leg of the floor portion 126.It will also be apparent that relatively short linear sections 130 a-130c could be utilized at the apex of the roof or ceiling portion 124 orfloor portion 126. Each of the relatively short arcuate sections 130a-130 c are disposed so that a tangent line taken at any location alongthe arcuate section extends at an acute angle, preferably at least 45°,relative to a plane extending normal to the longitudinal central axis Aof the trim cage 20.

It is contemplated that the flow channel 40 may have numerous shapes andsizes in addition to the chevron-based cross-sections illustrated inFIGS. 6-8. For example, as illustrated in FIGS. 9-12, variouscross-section configurations are demonstrated for non-limiting examplepurposes.

In FIG. 9, the flow channel 40 has a diamond shaped cross-sectional flowarea. The flow channel 40, according to this aspect, includes sections140 a-140 c shown for exemplary purposes as aligned in the direction offlow. It will be apparent that the sections 140 a-140 c may be ofdifferent sizes and offset relative to one another either in thedirection of the longitudinal central axis A of the trim cage 20 and/orin a direction transverse to the longitudinal central axis or acombination. In any event, the flow channel 40 has a V-shaped ceilingportion 144 and a V-shaped floor portion 146. Each leg of the ceilingand floor portions 144, 146 is a substantially planar surface. Theplanar surfaces are disposed at an acute angle relative to a planeextending normal to the longitudinal central axis A. The angle ispreferably at least 45°. The height of the flow channel 40 taken in adirection parallel to the longitudinal central axis A, in this aspect,maybe substantially equal to the width taken in a direction normal tothe longitudinal central axis. It will also be apparent that the heightmay be greater or lesser than the width depending on design applicationneeds.

In FIG. 10, the flow channel 40 has a rhomboidal shaped cross-sectionalflow area. The flow channel 40, according to this aspect, includessections 160 a-160 c shown for exemplary purposes as aligned in thedirection of flow. It will be apparent that the sections 160 a-160 c maybe of different sizes and offset relative to one another either in thedirection of the longitudinal central axis A of the trim cage 20 and/orin a direction transverse to the longitudinal central axis or acombination. The flow channel has a roof or ceiling portion 164 and afloor portion 166. The ceiling and floor portions 164, 166 includesubstantially planar surfaces that extend parallel to each other. Theplanar surfaces of the ceiling and floor portions 164, 166 are disposedat an acute angle relative to a plane extending normal to thelongitudinal central axis A. The angle is preferably at least 45°. Theplanar surfaces of the ceiling and floor portions 164, 166 are connectedby parallel extending planar surfaces 168. The parallel extending planarsurfaces 168 extend in a direction substantially parallel to thelongitudinal central axis A of the trim cage 20. The height of the flowchannel 40 taken in a direction parallel to the longitudinal centralaxis A, in this aspect, maybe substantially equal to the width taken ina direction normal to the longitudinal central axis. It will also beapparent that the height may be greater or lesser than the widthdepending on design application needs.

In FIG. 11, the flow channel 40 has an elongated hexagonal shapedcross-sectional flow area. The flow channel 40, according to thisaspect, includes sections 180 a-180 c shown for exemplary purposes asaligned in the direction of flow. It will be apparent that the sections180 a-180 c may be of different sizes and offset relative to one anothereither in the direction of the longitudinal central axis A of the trimcage 20 and/or in a direction transverse to the longitudinal centralaxis or a combination. The flow channel has a ceiling portion 184 and afloor portion 186. Each of the ceiling and floor portions 184, 186include a substantially planar surface. The planar surfaces of theceiling and floor portions 184, 186 are disposed at an acute anglerelative to a plane extending normal to the longitudinal central axis A.The angle is preferably at least 45°. The planar surfaces of the ceilingand floor portions 184, 186 are connected by parallel extending planarsurfaces 188. The parallel extending planar surfaces 188 extend in adirection substantially parallel to the longitudinal central axis A ofthe trim cage 20. The height H2 of the flow channel 40 taken in adirection parallel to the longitudinal central axis A, in this aspect,is substantially larger than the width W2 taken in a direction normal tothe longitudinal central axis. It will also be apparent that the heightH2 may be greater or lesser than the width W2 depending on designapplication needs. The flow channel 40 may be formed, if desired, sothat the height H2 extends in a direction substantially parallel to thelongitudinal central axis A for a distance that is greater than thethickness of the previously known stacked plate-type cage that wastypically about 0.125 inch.

In FIG. 12, the flow channel 40 has a quadrilateral trapezoid shapedcross-sectional flow area. The flow channel 40, according to thisaspect, includes sections 200 a-200 c shown for exemplary purposes asaligned in the direction of flow. It will be apparent that the sections200 a-200 c may be of different sizes and offset relative to one anothereither in the direction of the longitudinal central axis A of the trimcage 20 and/or in a direction transverse to the longitudinal centralaxis or a combination. The flow channel has a ceiling portion 204 and afloor portion 206. Each of the ceiling and floor portions 204, 206include a substantially planar surface of different widths that extendsubstantially parallel to each other. The planar surfaces of the ceilingand floor portions 204, 206 are disposed substantially normal to thelongitudinal central axis A. The planar surfaces of the ceiling andfloor portions 204, 206 are connected by planar surfaces 208. The planarsurfaces 208 are disposed at an acute opposite angles relative to aplane extending parallel to the longitudinal central axis A. The angleis preferably at least 45°. The height of the flow channel 40 taken in adirection parallel to the longitudinal central axis A, in this aspect,is substantially less than the width. It will also be apparent that theheight may be greater or lesser than the width depending on designapplication needs. As will be described below, in this particularaspect, the direction that the material is laid down with would besubstantially in the direction indicated by the arrow D2 and differentthan the direction that the material is laid down in other aspects.

Thus, a unitary or one-piece trim cage 20 is provided for controllingfluid flow energy, according to several aspects, that offers significantadvantages such as flexible design options, economy and ease ofmanufacturing relative to previously known stacked plate-type cages.

The method of manufacturing the unitary trim cage 20, according to yetanother aspect, is important to producing the trim cage, economical andvery flexible in its ability to quickly incorporate design changes intofinished product. The unitary trim cage 20 is made as a one-piececomponent by a direct metal laser melting (DMLM) that concurrentlydefines the flow channels 40 without the need for any internal support.The method includes providing powdered metal material to define the body21 and flow channels 40 of the trim cage 20. The body 21 is preferablyin the form of a cylindrical tube with a longitudinal central axis A.The body 21 includes the base 22 (FIG. 1-2) that is essentially a flatplate with a centrally located opening. The body 21 also includes thecap 24 and located at an opposite end from the base 22. The cap 24 isalso essentially a flat plate with a centrally located opening. The body21 has a cylindrical inner opening defined by the inner surface 26extending along the entire axially extending for the length of the body21 and between the base 22 and cap 24. The body 21 also has thecylindrical outer surface 28 disposed coaxially about the axis A and theinner surface 26 and extending between the base 22 and cap 24.

The trim cage 20 is preferably manufactured by a suitable materialadditive manufacturing process. One such process is direct metal lasermelting. In such a method, material is first laid down in the form of apowdered substance in a series of layers, collectively illustrated as240 in FIG. 6, such as a suitable metal for the application. A laserthen melts each layer of the laid down powder on a previous laid downlayer that melted and solidified.

Flow channels 40 extend between the inner surface 26 (i.e., the inneropening) and outer surface 28. The body 21 is integrally formed asone-piece by successive layer material additive manufacturing (additivemanufacturing) to define solid portions of the body and the flow channel40 as a void space. The flow channel 40, according to one aspectillustrated in FIG. 6, has a V-shaped ceiling portion 84 and a V-shapedfloor portion 86 spaced from the ceiling portion. The ceiling portion 84is connected to the floor portion 86 by a pair of substantiallyextending planar surface portions 88. Each of the legs of the ceilingportion 84 and the floor portion 86 is disposed at an angle relative toa plane containing one of the layers 240 (FIG. 6) of material definingthe body 21.

Material is added to the body base 22 along a lay down direction D1(FIG. 6) in successive layers 240. The material is added in such amanner to maintain the surface of the inner opening defined by the innersurface 26 and define at least one tortuous flow channel extendingbetween the inner opening surface and the outer surface. The surfacesdefining the opening 26 of the trim cage 20 can be manufactured withrelatively good precision and accuracy so that it may not require finishmachining to precisely fit over the valve plug.

The flow channels 40 are essentially void spaces formed within theunitary body 21 and require no support during manufacture in order todefine the flow channels. The tortuous flow channel 40 is comprised of aplurality of sections. Each section of the flow channel is offsetrelative to an adjacent section in the lay down direction D1. At least aportion of each section extends at an angle relative to direction ofadditive lay down of at least 45°. The numerous layers are laid downuntil the desired length of the body 21 and number of flow channels 40are provided. Material is then added to define the body cap 24 in such amanner to maintain the inner surface and the outer surface to completethe body 21 of the trim cage 20.

The lay down of each layer 240 is illustrated in FIG. 6 as forming theceiling portions 84. The same concept for forming the ceiling portion 84is used in forming the floor portions 86 and will suffice to describeboth. Each successive layer overlaps the previous layer by apredetermined relatively small dimension, such as less than half of thediameter of the powdered particle used, to define the angled planarsurface of the leg of the ceiling portion 84 by forming a series ofrelatively small “steps”. Each layer can be laid down with a thicknessin the range of about 20 to 200 microns (0.0008 to 0.008 inch) dependingon the material, size of powder and laser energy applied. Of course, itis to be appreciated that different thicknesses, and specificallythinner, finer layers may be employed.

This lay down of successive layers 240 also allows the definition ofsubsequent overlapping surfaces to define curved or linear surfaces,such as those shown in FIGS. 7 and 8, that are disposed at an angle tothe longitudinal central axis A. The direction of material lay down ispreferably parallel to the longitudinal central axis A. At least aportion of each section extends at a suitable acute angle relative todirection of additive lay down and preferably at least 45°. Thus, nointernal support is needed to define the void spaces of the flowchannels 40.

The material that the trim cage 20 is made from is selected from thegroup of metal powders comprising: stainless steel based powders; nickel& cobalt based powders; iron based powders; titanium based powders;aluminum based powders; and combinations thereof. It will be apparentthat any suitable material may be employed according to this aspect.

A one-piece unitary body 21 is, therefore, provided with flow channels40 formed by the body 21 manufacturing process. The flow channels 40 areformed without the need for support of surfaces not extending in thedirection of material lay down. The inner surface 26 of the trim cage 20is precision fit to the plug size by the manufacturing process andrequires minimal or no further machining to provide the desired insidediameter dimension and surface finish.

An alternate aspect of the manufacturing process is illustrated in FIG.12. The direction of material lay down D2 may be orthogonal relative tothe longitudinal central axis A, as illustrated in FIG. 12. Material canbe added to the body 21 along the lay down direction D2 (FIG. 12) thatis not oriented along the axis of the body. The material is added insuch a manner to maintain the inner surface 26 and define the tortuousflow channels 40 extending between the inner surface 26 and the outersurface 28. The flow channels 40 are essentially void spaces within theunitary body 21 and require no support to define the flow channels. Theflow channel 40 is formed by material additive layer process in the laydown direction D2. Each surface 208 extends at an angle relative todirection of additive lay down D2 of at least 45°. The angled surfaces208 are formed by the layer additive process as described above forceiling portions 84 and floor portions 86 illustrated in FIG. 6. Thatis, the surfaces 208 are created by overlapping successive layers ofmaterial to create a series of relatively small “steps.”

The trim cage 20 offers numerous advantages over heretofore known platetype of cages. For example, little or no machining of the inner openingis required. There is no need to be concerned about the flatness of aplate or to machine flow channels in plates. There is no need to stackplates or to align them. There is no brazing required. Thus, the qualityproblems that ensue from the difficult brazing process are avoided. Theheight of a flow channel can be larger than width and more than thethickness of plates that were used in previously known cages. Also, suchcan provide for some additional/different advantages. For example, astack can have a number of plates (e.g., one hundred plates) and thenatural tolerance of commercially available plate stock would lead todesign with many more plates than necessary to ensure we have enoughstack height. This frequently results in having to machine off somematerial (e.g., an inch) from top and bottom caps that are brazed ontothe stack. This present additive technique can help remove thissituation and such save time and money.

From the above description of at least one aspect of the invention,those skilled in the art will perceive improvements, changes andmodifications. Such improvements, changes and modifications within theskill of the art are intended to be covered by the appended claims.

Certain terminology is used herein for purposes of reference only, andthus is not intended to be limiting. For example, terms such as “upper”,“lower”, “above”, and “below” refer to directions in the drawings towhich reference is made. Terms such as “left”, “right”, “front”, “back”,“rear”, “bottom” and “side”, describe the orientation of portions of thecomponent within a consistent but arbitrary frame of reference which ismade clear by reference to the text and the associated drawingsdescribing the component under discussion. Such terminology may includethe words specifically mentioned above, derivatives thereof, and wordsof similar import. Similarly, the terms “first”, “second” and other suchnumerical terms referring to structures do not imply a sequence or orderunless clearly indicated by the context.

When introducing elements or features of the present disclosure and theexemplary aspects, the articles “a”, “an” and “the” are intended to meanthat there are one or more of such elements or features. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements or features other than thosespecifically noted. It is further to be understood that the methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. It is also to be understood that additional oralternative steps may be employed.

Although the description has been shown and described with respect toone or more embodiments, aspects, applications or implementations, itwill occur to those skilled in the art based upon a reading andunderstanding of this description and the drawings that equivalentalterations and modifications may be made without detracting from thespirit and scope of the embodiments, aspects or implementations in thedescription. The description and claims are intended to include all suchmodifications and alterations.

What is claimed is:
 1. A valve component for controlling fluid flow, thevalve component comprising: a body having a first surface and a secondsurface; at least one tortuous flow channel extending between the firstsurface and the second surface, the flow channel at least partiallydefined by a floor portion and a ceiling portion; the body being formedas one-piece by additive manufacturing to concurrently define the flowchannel as a void space; and wherein at least one of the floor portionand ceiling portion being disposed at an acute angle relative to a planecontaining a layer of material forming the body.
 2. The valve componentof claim 1, wherein the acute angle for the at least one of the floorportion and ceiling portion is at least 45°.
 3. The valve component ofclaim 1, wherein a cross-sectional flow area of the flow channelincreases as the flow channel extends from the first surface to thesecond surface.
 4. The valve component of claim 1, further including atleast one planar surface extending between the floor portion and theceiling portion.
 5. The valve component of claim 1, further including asecondary flow channel extending from the flow channel to the secondsurface.
 6. The valve component of claim 1, wherein a height of the flowchannel is greater than a width of the flow channel.
 7. The valvecomponent of claim 1, wherein at least one of the floor portion andceiling portion includes a planar surface.
 8. The valve component ofclaim 1, further including a plurality of tortuous flow channelsextending between the first surface and second surface of the body. 9.The valve component of claim 1, wherein at least one of the floorportion and ceiling portion of the flow channel has a pair of surfacesthat intersect at an acute angle, each of the pair of surfaces alsobeing disposed at an acute angle relative to the plane containing thelayer of material forming the body.
 10. The valve component of claim 1,wherein the tortuous flow channel comprises at least two sections, eachsection of the flow channel is offset relative to an adjacent section ina direction orthogonal to the plane containing the layer of materialforming the body.
 11. A trim cage for controlling fluid flow, the trimcage comprising: a unitary body having a substantially tubularconfiguration with a longitudinal central axis, the body having an innersurface and an outer surface; at least one tortuous flow channelextending through the body from the inner surface to the outer surfacefor fluid flow therethrough, the tortuous flow channel including atleast two sections, each section of the flow channel is offset relativeto an adjacent section, each section of the flow channel has an axialfloor portion and axial ceiling portion; and wherein each of the axialfloor portion and axial ceiling portion are disposed at an acute anglerelative to a plane extending normal to the longitudinal central axis ofthe body.
 12. The trim cage of claim 11 wherein a cross-sectional flowarea of the flow channel increases in the direction extending from theinner surface to the outer surface.
 13. The trim cage of claim 11,further including at least one axially extending surface between theaxial floor portion and axial ceiling portion.
 14. The trim cage ofclaim 11, wherein the body is formed as one-piece by additivemanufacturing while concurrently defining the tortuous flow channel. 15.The trim cage of claim 11, further including a plurality of tortuousflow channels extending between the inner surface and outer surface ofthe body.
 16. The trim cage of claim 11, wherein at least one of theaxial floor portion and axial ceiling portion of the flow channel has apair of surfaces that intersect at an acute angle, each of the pair ofsurfaces being disposed at an angle of at least 45° relative to theplane extending normal to the longitudinal central axis of the body. 17.A method of manufacturing a unitary trim cage, the method comprising thesteps of: providing at least one layer of material to define a body basewith an inner opening surface and an outer surface; adding successivelayers of material to the body base along a lay down direction and insuch a manner to maintain the inner opening surface and define at leastone tortuous flow channel extending between the inner opening surfaceand the outer surface, the tortuous flow channel including a pluralityof sections; wherein each section of the flow channel is offset relativeto an adjacent section and the surfaces defining the flow channel areaccomplished without internal support, and at least a portion of eachsection extends at an acute angle relative to direction of additive laydown; and adding at least one layer of material to define a body cap insuch a manner to maintain the inner opening surface and the outersurface.
 18. The method of claim 17, wherein the trim cage has an axisand the layers of material added being substantially in a planeextending orthogonally relative to the axis, the acute angle being atleast 45° and each section of the flow channel is offset relative to anadjacent section in the lay down direction.
 19. The method of claim 17,wherein the trim cage is made by a direct metal laser melting additivelayer manufacturing process.
 20. The method of claim 17, wherein thematerial is selected from a group of metal powders comprising: stainlesssteel based powders; nickel & cobalt based powders; iron based powders;titanium based powders; aluminum based powders; and combinationsthereof.